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2002 T Bird fuel pump replacement.

Discussion in '2002 - 2005 Ford Thunderbird' started by edward301, Mar 10, 2018.

  1. My fuel pump looks like it is shot. Started car one day, ran for 10 seconds, then died. Fuse for fuel
    pump blew. Replaced fuse but no pump. Checked fuel pressure fitting under hood, and no pressure.

    Have opened up area behind seat to expose fuel pump area. Anyone have any hints on how to remove
    ring that secures fuel pump.
  2. Some additional information, I am original owner, car has 11957 miles, I did check electric plug
    on fuel pump, and am getting voltage, so pretty sure pump is bad.

    The plastic ring securing pump looks pretty flimsy, so do not want to break it, hopefully some one
    has removed pump before and has some handy hints.
  3. Gus Gutz

    Gus Gutz Well-Known Member Lifetime Donor

    this may help. There are two pumps.
  4. cdf912

    cdf912 Active Member Lifetime Donor

    First, the answer to your question. You can rent the tool from many auto parts stores. I have also seen some YouTube videos where people use a a 1/2 wide dull chisel and a hammer to lightly tap along the ridges to get the ring to rotate, others have used a strap wrench like you would use for oil filters. BUT before you attempt this, I recently purchased the Ford Workshop manuals and the procedure is to 1. first drain the tank, then you are to loosen the gas tank straps 1 inch, this will bring the pumps more inline with the openings in the sheet metal so that you have more room to deal with the hoses, etc. If you need me to, I can take pics of the pages for you to complete this repair.
    John Hayman and tbird like this.
  5. Gus Gutz

    Gus Gutz Well-Known Member Lifetime Donor

    I printed this from my workshop manual.

    Attached Files:

  6. Pelagic

    Pelagic Well-Known Member Lifetime Donor

    Just did this exact same job for my 2001 Passat. Pain. Didn't have to move the tank, but I was surprised that the "fuel pump" consists of a 2-piece plastic contraption.......which has been immersed in gasoline for years. So all parts are hard and brittle. Hoping when it comes time to do this on the TBird that it is easier. Still.........probably saved myself a grand.
    John Hayman likes this.

  7. Replace both pumps be careful with gaskets.
    John Hayman likes this.
  8. Mentioned in other post bird is all fixed. New pump, new battery, and new AC
    compressor. Very cold ac.
    John Hayman likes this.
  9. Edward did you change the AC compressor yourself? Last summer I put a set of gauges on mine and all the pressures were low so I'm sure the valves in the compressor are bad.
    John Hayman likes this.
  10. Yes I did, not hard but tight space, have to jack up the left front. Will need a
    vacuum pump to evacuate the system, and a electronic scale to install the correct
    amount of 134a Freon, ( 48 ounces ).

    A new compressor with clutch was $198.00, fit perfectly.
    John Hayman likes this.
  11. So My code is P1237. So Is that the driver side fuel pump or the passenger side. I believe I have two fuel pumps in the car.. What is the best manual for it
    John Hayman likes this.
  12. Gus Gutz

    Gus Gutz Well-Known Member Lifetime Donor

    they make it look easy in my manual

    Attached Files:

  13. While the manual says pinch the tabs and pull straight up on the lines, this may or may not work. Even with wire wrapped around the fittings I could not get the fuel pump pipes to extract from the pump housing. Even on the bench,
    (after I cut the lines, they were kinked anyway), I pulled with large pliers and they would not come out. I guess they were heated on by age and heat. Sooo I have to buy lines and module to repair. Ben
    John Hayman likes this.
  15. Hi there. I just replaced mine. Matco t makes a really nice tool. You will need a long extension so you have leverage. Tricky part is the gasket. Also you have to reach into the gas tank and un clip the fuel pump. The ring is hard to get started and you fight with the gasket. Took me 5 times to hold that gasket in place apply pressure to get the ring back on. And don’t let the fuel pump spin. :(. But I got it. You can buy the tool online
  16. Lulu, did you go from the bottom to replace the fuel pump like Ford manual says or did you come in from the top like the above video? What is the "official" name of the tool?

  17. I think many retro bird owners suffer from "fuel pump anxiety " and I too had an experience with my '05 that caused one of those "Oh No" moments. Car would start and then almost immediately stop. Emotionally prepared for the cost of a dreaded fuel pump replacement, my dealer then determined the problem to be the fuel rail pressure sensor. Way less expensive! Though relieved at the time, I think I'm still going to go ahead and replace my fuel pump just to take care of all of that anxiety. Just wanted to share my story.
  18. Gus Gutz

    Gus Gutz Well-Known Member Lifetime Donor

    Too many owners fo not drive their cars enough. The fuel pump fail because of this. I read too often how people let their cars sit for 6 months and then wonder why their fuel pumps are bad.
  19. I've heard that too. Also running on or close to empty and a dirty fuel filter. I have had this car for a little over four years and have enjoyed it a lot. But it seems like at least once a year I get a big expensive hit. Now I worry about the fuel pump leaving me stranded.
    Elsie likes this.
  20. " But it seems like at least once a year I get a big expensive hit. Now I worry about the fuel pump leaving me stranded."

    Me too. I've had my Bird for 5 or 6 years. Every year I've had to stick a MIN. of $1500 in to it, and yeah I've become paranoid about the fuel pump going out. I originally purchased my Bird with the thought it would be my road car for weekend trips and maybe a winter run to FL. After a few years of ownership I decided I'm not going to drive this vehicle more than 10 miles ($100 tow charge) from home. I drive it to the sports bar to have a draft and some wings and to the golf course and that is it anymore. Common sense would/is saying get rid of it, you got a lemon, but that trip home in the fall from the golf course when it is 55 - 60, top down, heated seats on, well...…….. I'll keep it - one more time till something else breaks.

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